well, so I went to change the rear disc on my freelander 2 and all of a sudden a rubber piece came off and the brake fluid started pouring out.

As you can see in the picture attached, it is the rubber around the piston which came right off.



Is there any way how I can push it back in? I tried using a flat screw but i was not able to put it back in! and i did not try too hard since I was afraid of damaging the rubber.

Last edited by mad85 on 11th Feb 2017 5:29 pm. Edited 1 time in total

i see now it should have been in the maintenance section ... sry!

I suppose your best hope is to put it in maintenance mode, unbolt the motor from the rear of the calliper and refit the piston. To make it easier I'd suggest camping the hose, removing the calliper, remove the bleed screw and doing it on a bench. Should go back in without too much trouble as long as it is forced in straight. Past: FL2 TD4 HSE Auto
Evoque SD4 Dynamic Lux Auto
Present: Audi A3 S Line.

thanks for your reply - what do you mean by camping the hose?

There are special brake hose clamps or use mole grips with low pressure to stop fluid escaping from the rubber hoses.

As an apprentice working on Jaguars at the main dealers nearly 50 years ago. We would strip the Dunlop calipers fully and get really fine wet and dry paper and with paraffin clean the pistons and bores etc . Once clean and dry we used a new rubber kit to rebuild with a little new fluid and specialist rubber grease. Pressing the pistons back in had to be done slowly and straight. No throwaway parts then. FL2 MY10 TD4 GS traded in at 2 years
FL2 MY13 TD4 GS Current

mad85 wrote:

thanks for your reply - what do you mean by camping the hose?

The brake manufacturers make special clamps which don't damage the hose. Should be widely available. I've got one I bought years ago but never needed to use. Ex AA Series III LWB Safari - Gone
300TDi Disco (bought new - terrible car) sent back after 18 months
Freelander 1 Estate - leased, given back at end of lease
200TDi Disco (bought from a mate with 100,000 on the clock) - Gone
Disco 2 TD5 - sold and exported to France
FR2 TD4 GS - Gone
FR2 SD4 HSE - Now changed for a DS
New model ex-demo Evoque S 180 in white
Unable to order a new DS, so gave up. Now have a Volvo S90 Recharge.

Yorky Bob wrote:

There are special brake hose clamps or use mole grips with low pressure to stop fluid escaping from the rubber hoses.

As an apprentice working on Jaguars at the main dealers nearly 50 years ago. We would strip the Dunlop calipers fully and get really fine wet and dry paper and with paraffin clean the pistons and bores etc . Once clean and dry we used a new rubber kit to rebuild with a little new fluid and specialist rubber grease. Pressing the pistons back in had to be done slowly and straight. No throwaway parts then.

I once had a caliper bleed nipple sheer off on my Morris Marina so I removed the caliper and set of to the dealer. The guy at the parts dept said that calipers were very expensive and it would take ages to get one so he recommended getting a set of drills and carefully drilling it out until I could get a screw extractor or small screwdriver in the hole. It took me all afternoon with a hand drill but I did it. He even gave me a new bleed nipple. Can't see anyone getting that sort of advice or service these days. 3 x FL1 2 manual + 1 auto
5 x FL2 4 manual + 1 auto
Now Discovery Sport P250 MHEV SE

thanks for the replies guys. managed to put the seal back in and compress the piston. Now I just need to bleed the system.. unfortunately a lot of fluid came out so I think i will have to flush the whole thing.

ps, this video shows a good way of compressing the piston if you missed on putting the epb in maintenance mode:

dorsetfreelander wrote:

I once had a caliper bleed nipple sheer off on my Morris Marina so I removed the caliper and set of to the dealer. The guy at the parts dept said that calipers were very expensive and it would take ages to get one so he recommended getting a set of drills and carefully drilling it out until I could get a screw extractor or small screwdriver in the hole. It took me all afternoon with a hand drill but I did it. He even gave me a new bleed nipple. Can't see anyone getting that sort of advice or service these days.

mad85 wrote:

thanks for the replies guys. managed to put the seal back in and compress the piston. Now I just need to bleed the system.. unfortunately a lot of fluid came out so I think i will have to flush the whole thing.

ps, this video shows a good way of compressing the piston if you missed on putting the epb in maintenance mode:

Lots of workshop practice that would have seen my arse kicked as an apprentice.

Use of tools as hammer. ?
Muck on the new working surfaces etc etc etc.
Ass about face checking fluid level.
I would be using copper grease in some areas (sparingly) on rebuild of disc etc.

Those bolts with a coloured film I guess will only work at a set torque as the old sports cars were wired on or had spring washers when not using a torque wrench.

Feel free to add more views you boys still in the better end of the trade. FL2 MY10 TD4 GS traded in at 2 years
FL2 MY13 TD4 GS Current

so, the rubber seal broke while I was trying to put it together and since it does not come as a repair kit, I had to order the whole caliper, for around 200eur hope i receive it soon at least. I am also less concerned that I might introduce dirt in the system when the rubber seal came off now.

Now, my next question: The situation I suspect is that I will have one caliper that is extended and the new one which will be retracted. Will this cause any issues with the electric parking brake? I think it makes sense that before I connect the motor, I set the EPB to maintenance mode so it also retracts the other one... does that make sense?

Thanks!

I would advise you to put the EPB in maintenance mode anyway just to be safe - then when you turn it off both calipers will be activated evenly
Get some pictures of before and after so we can all see the problem you are fixing
Good Luck  No Longer the owner of a 2013MY Fuji White GS

"Fiat Lux" a philosophy not a car

[quote="Yorky Bob"]

mad85 wrote:

Those bolts with a coloured film I guess will only work at a set torque as the old sports cars were wired on or had spring washers when not using a torque wrench.

Feel free to add more views you boys still in the better end of the trade.